Regulator for air outlet

ABSTRACT

A regulator for regulating airflow through an air outlet includes a plurality of louver blades integrated with axis portions supported at bearing holes and interconnected through an interlocking member; a supporting plate with the bearing holes attached to an air outlet; and an elastic portion provided on the supporting plate to be capable of deforming along an axis of the louver blades. Also, the regulator may include a damper; a manual operating member for tilting the louver blades and damper; and two gears engaging each other and disposed at an interconnecting portion between the manual operating member and the damper. One of the gears is formed in two portions separated along an axis and provided coaxially. The two portions have slightly shifted pitch, and are able to displace with each other in a circumferential direction with elasticity.

BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT

[0001] The present invention relates to a regulator for regulatingairflow through an air outlet. In particular, the invention relates to aregulator for regulating airflow through an air outlet having multiplelouver blades integrated with a shaft supported in a bearing hole andinterconnected via an interlocking member.

[0002] In an air outlet through which air flows out into a carcompartment of an automobile, a louver is provided for adjusting a winddirection. The louver is generally interconnected to multiple louverblades through an interlocking member such as a link mechanism or cammechanism. The multiple louver blades provided in the air outlet canchange a direction as a whole by manually rotating an operating membersuch as a dial partially exposed at a front surface of an instrumentpanel (see Japanese Patent Publications (KOKAT) No. 63-112210 and No.11-70814).

[0003] The louver blades composing the louver directly receive a windpressure, thus the louver blades tend to vibrate if there is a gap,thereby causing a squeak and rattle. In order to support the louverblade without a gap, a shaft portion formed integrally on the louverblade must fit tightly to a bearing hole formed in a framing member.

[0004] However, in order to tightly fit the shaft to the bearing hole,high tolerance in manufacturing and assembly is required, therebycomplicating the manufacturing process. Also, the framing member forsupporting the louver and louver blade is generally formed of aninjection molded thermoplastic. However, due to a change in temperatureor an extent of air conditioning, the louver blades and the framingmember may be deformed under heat. Thus, it is difficult to adjust thelouver blade with a constant force due to the deformation.

[0005] Moreover, in the link mechanism or cam mechanism as disclosed inJapanese Patent Publications, it is difficult to obtain a linearrelationship between a rotational angle of the manual operating memberand a tilting angle of the louver blades. It is also difficult tooperate with a constant control force over the entire operation range,thereby preventing a smooth operation.

[0006] The present invention has been made in order to solve theproblems in the conventional technology, and a main object is to providea regulator for regulating airflow through an air outlet that can beoperated smoothly and reduce a gap, without complicating themanufacturing process and being affected by the temperature change.

[0007] Further objects and advantages of the invention will be apparentfrom the following description of the invention.

SUMMARY OF THE INVENTION

[0008] In order to achieve the above-mentioned objects, according to thepresent invention, a regulator for regulating airflow through an airoutlet includes a plurality of louver blades interconnected through aninterlocking or interconnecting member; a damper provided in an airpath; a manual operating member for tilting the louver blades anddamper; and two gear means engaging with each other and disposed at aninterconnecting portion between the manual operating member and thedamper. One of the gear means is formed in two portions separated alongan axis and provided coaxially. The two portions are slightly shifted inpitch, and are connected to be able to displace with each other in acircumferential direction with elasticity. With this configuration, thetwo portions have the shifted pitch and contact the inside of the othergear tooth with the elasticity, thereby preventing a backlash.

[0009] Also, the louver blades and the interlocking member may beconnected through an axis direction pin projecting at a location offsetfrom a rotational center of the louver blades, and a long hole with along axis situated on a line parallel to a straight line between asubstantial middle point of a rotational range of the pin and a centerof tilting of the louver blades. With this configuration, it is possibleto minimize a frictional angle between the long hole and the pin duringthe tilting motion of the louver blades.

[0010] Further, rotational resistance applying means may be provided inthe rotational center axis of the manual operating member. Thus, a gapat the manual operating member can effectively be eliminated, therebypreventing a gap at the louver blades connected to the manual operatingmember.

[0011] According to another aspect of the present invention, a regulatorfor regulating airflow through an air outlet includes a plurality oflouver blades integrated with axis portions supported at bearing holesand interconnected through a link plate; a supporting plate with thebearing holes attached to an air outlet; and an elastic portion providedon the supporting plate and being capable of deforming along an axis ofthe louver blades. With this configuration, the supporting plate canelastically deform to absorb a heat deformation between the air outletand the louver blades.

[0012] Further, the elastic portion may be provided on both ends of thesupporting plate or the elastic portion may have a branched portion toimprove stability in attaching the supporting plate to the air outlet.

[0013] Further, O-rings formed of a silicon resin with self-lubricitymay be placed at a supporting shaft of the rotational operating memberto displace the interlocking member in the horizontal direction, therebyreducing a fluctuation in torque with the temperature change.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014]FIG. 1 is a perspective view of an instrument panel of anautomobile according to the present invention;

[0015]FIG. 2 is a perspective view of an air outlet according to thepresent invention;

[0016]FIG. 3 is a left side view of the air outlet shown in FIG. 2 in astate where a damper is closed;

[0017]FIG. 4 is a left side view of the air outlet shown in FIG. 2 in astate where the damper is opened;

[0018]FIG. 5 is a sectional right side view of the air outlet shown inFIG. 2 in a state where the damper is closed;

[0019]FIG. 6 is a sectional right side view of the air outlet shown inFIG. 2 in a state where the damper is opened;

[0020]FIG. 7 is a partial bottom view of the air outlet shown in FIG. 2;

[0021]FIG. 8 is an enlarged sectional view of rotational resistanceapplying means;

[0022]FIG. 9 is a front view of an essential portion in a state that anattaching portion of vertical louver blades of the air outlet shown inFIG. 2 is partially removed;

[0023]FIG. 10 is a plan view of an end portion of an upper supportingplate;

[0024]FIG. 11 is a perspective view of an essential portion of the airoutlet shown in FIG. 2; and

[0025]FIG. 12 is an enlarged left side view of a portion connectingbetween a horizontal louver blade and an interlocking member.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0026]FIG. 1 shows a surrounding of an instrument panel P in anautomobile where the present invention is applied. At both right andleft ends and a center of the instrument panel P, air outlets A areprovided. Each of the air outlets A is connected to an air duct providedinside the instrument panel P, and a blower blows air into a carcompartment through an air conditioning system.

[0027] As shown in FIG. 2, the air outlet A includes a case 2 having arectangular hollow shape; a flange 1 formed on a connecting port of thecase 2 on the instrument panel P facing the car compartment; a pluralityof horizontal louver blades 3 supported on an axis to be able to tiltfreely and disposed in the case 2; a plurality of vertical louver blades4 supported on an axis to be able to tilt freely and disposed in thecase 2; and a damper 5 (see FIG. 3) having a butterfly valve forcontrolling airflow from an air duct (not shown).

[0028] The horizontal louver blades 3 are tilted around a horizontalaxis for shifting a vertical wind direction through a rotationaloperation of a side dial 6 provided at a left end of the flange 1 shownin FIG. 2. The vertical louver blades 4 are tilted around a verticalaxis for shifting a horizontal wind direction through a rotationaloperation of a underneath dial 7 provided at a lower end of the flange 1shown in FIG. 2.

[0029] The side dial 6 is supported on a sidewall of the case 2 to beable to rotate freely. A part of an outer circumferential surface of theside dial 6 is slightly exposed from the front surface of the flange 1.The part exposed from the front surface of the flange 1 can be operatedto rotate with a fingertip. Also, the underneath dial 7 is supported onthe bottom wall of the case 2 with an axis to be able to rotate freely.A part of the outer circumferential surface of the underneath dial 7slightly projects from the front surface of the flange 1 like the sidedial 6. The part exposed from the front surface of the flange 1 can beoperated to rotate with a fingertip.

[0030] A pinion 8 coaxial with a central axis of rotation is formedintegrally on a lateral surface of the side dial 6, as shown in FIGS. 3and 4. A sector gear 9 engages the pinion 8.

[0031] A sector gear 9 is supported with an axis to be able to rotatefreely on the sidewall of the case 2 diagonally lower front (an engineside) side relative to the rotational center of the side dial 6. Arocker arm 10 projects from the rotational center toward the engineside. At an end of the rocker arm 10, a long hole 11 with one end benttoward an outward direction is formed in roughly an L-shape. In the longhole 11, an end of a lever member 12 integrated on the rotational centeraxis of the damper 5 is connected.

[0032] When the side dial 6 is rotated downward (in the arrow direction)in a state that the damper 5 is closed as shown in FIG. 3, the rockerarm 10 rotates left due to an engagement between the pinion 8 and thesector gear 9. Then, an outward extension 11 a at an end of the longhole 11 formed at an end of the rocker arm 10 pushes a pin 12 a fixed tothe end of the lever member 12 to drive the damper 5 in the openingdirection. Because a rotational radius of the lever member 12 is smallerthan a curvature of the long hole 11, the pin 12 a at the end of thelever member 12 is aligned with the arc-shaped part of the long hole 11at the end of the rocker arm 10 when the damper 5 reaches at a fullopening position as shown in FIG. 4. Therefore, the damper 5 stays atthe full opening position, and the side dial 6 can continue to rotatefurther downward within a limit of the long hole 11.

[0033] The plurality (for example five) of the horizontal louver blades3 are supported at both ends with the horizontal axes in an inner spacebetween right and left sides of the case 2. And as shown in FIGS. 5 and6, a supporting axis 13 of each horizontal louver blade 3 is located atan upper edge of a rear side of the horizontal louver blade 3 in aclosed state (see FIG. 5), and is located next to an upper front edge ofthe horizontal louver blade 3 in an opening state (see FIG. 6). In theclosed state as shown in FIG. 5, each of the horizontal louver blades 3is lined up with no space along the front arc surface of the flange 1.In the open state as shown in FIG. 6, each of the horizontal louverblades 3 is arranged to extend parallel to an appropriate gap inbetween.

[0034] An arm 14 projects on a rear side of each horizontal louver blade3. The arm 14 is located on a lower edge of the rear side of thehorizontal louver blade 3 in the closed state, and is located next to anupper rear edge of the horizontal louver blade 2 in the open state. Inother words, the supporting axis 13 and the arm 14 are provided in aroughly symmetric position relative to a centerline along a longitudinaldirection of the horizontal louver blades 3.

[0035] Each edge of the arms 14 is interconnected through aninterlocking or interconnecting member 15 having a comb teeth shape. Thearms 14 and the interlocking member 15 are connected to be able torotate relatively, and all of the horizontal louver blades 3 areinterconnected to be tilted at once by moving the interlocking member 15up and down.

[0036] At the middle of the interlocking member 15 in the verticaldirection, a projection 16 is formed to project toward the engine side.In the projection 16, a long hole 17 is formed along the horizontaldirection.

[0037] A pin 18 projecting from the inner side of the side dial 6 isinserted in the long hole 17. The pin 18 passes through a long hole 19formed on the sidewall of the case 2 and having an arc shape around therotating shaft of the side dial 6, thereby regulating its movable range.

[0038] In the state that the damper 5 is closed as shown in FIG. 5, eachof the horizontal louver blades 3 is also closed. When the side dial 6is rotated downward from the state, the interlocking member 15 movesupward with the pin 18 integrated with the side dial 6, and each of thehorizontal louver blades 3 connected to the interlocking member 15 tiltsin the opening direction all at once. At the same time, the damper 5opens as described above. After the damper 5 is fully opened as shown inFIG. 6, each of the horizontal louver blades 3 continues to tilt furtherin the opening direction within the regulated range by the arc-shapelong hole 19 formed in the sidewall of the case 2. The vertical winddirection can be regulated according to the tilting angle of eachhorizontal louver blade 3 at this time.

[0039] The plurality (for example five) of the vertical louver blades 4are supported with supporting axis 20 a and 20 b projecting from top andbottom ends at a top wall 2R and a bottom wall 2B of the case 2, so thatthe vertical louver blades 4 tilt horizontally around the vertical axis.

[0040] On a lower edge of one of the vertical louver blades 4 located atthe middle among the vertical louver blades 4, a pin 21 is disposedvertically in a position shifted in front of the supporting axis 20 b.As shown in FIG. 7, the pin 21 passes through a long hole 22 formed inthe bottom wall 2B of the case 2 and having an arc shape around thelower dial 7. An end of the pin 21 engages the long hole 23 formed inthe lower dial 7 along the horizontal direction. Also, projection (notshown) are disposed on the other vertical louver blades 4 at positionscorresponding to the pin 21 of the middle vertical louver blade 4. Allof the vertical louver blades 4 are interconnected through theengagements of the common line plate 24 with the projections and the pin21.

[0041] With this configuration, when the lower dial 7 is rotatedhorizontally, all of the vertical louver blades 4 swing horizontally allat once.

[0042] Rotational resistance applying means 25 is provided at a portionwhere the lower dial 7 is attached to the bottom wall 2B of the case 2.Thus, an adequate rotational resistance is provided to the verticallouver blades 4, thereby preventing the vertical louver blades 4 fromflapping.

[0043] As shown in FIG. 8, the rotational resistance applying means 25,which is provided at the portion where the lower dial 7 is attached tothe bottom wall 2B of the case 2, includes a cylinder portion 41integrated with the lower dial 7; a boss portion 42 projecting downwardat the bottom wall 2B; and a plurality (2 in the current embodiment) ofO-rings 43 disposed in series in the axial direction in a circular spaceRG formed in a fitting portion. The cylinder portion 41 is fixed not tocome out with a screw 44 screwed in the center of the boss portion 42.

[0044] The o-rings 43 are formed of a silicone resin withself-lubricity, thereby reducing torque fluctuation caused by atemperature change. In addition, when the o-rings are used, therotational resistance can be easily adjusted through the number of therings or adjustment of a radial size of the circular space RG formounting the o-rings. This rotational resistance applying means 25 canbe applied to the supporting portion of the side dial 6 as well. Therotational resistance applying means is not limited to the O-rings, and,for example, silicone grease and the like can be filled in the space.

[0045] As shown in FIG. 9, the supporting axes 20 a and 20 b at top andbottom of the vertical louver blades 4 are fitted in the bearing holes27 formed in the supporting plates 26U and 26L (not shown) attached tothe top wall 2R and bottom wall 2B of the case 2. The supporting plates26U and 26L are made of an elastic synthetic resin. The supportingplates 26U and 26L may be molded by the two-material molding method withinserting the pre-molded supporting axes 20 a and 20 b of the verticallouver blades 4, thereby reducing the number of manufacturing steps.

[0046] Among the supporting plates 26U and 26L, as shown in FIGS. 9 and10, the upper supporting plate 26U attached to the top wall 2R isprovided with a branched portion 28 bending upward at each of the rightand left ends thereof. Only ends of the branched portion 28 abut againstan under surface of the top wall 2R with vertical elasticity. Due tothis structure, the upper side supporting plate 26U is supported morestably in the horizontal direction.

[0047] An upward projecting portion 29 is formed at the center of theupper side supporting plate 26U in the left-right direction. Theprojecting portion 29 engages a groove 30 extending in the back-forthdirection and formed in the lower surface of the top wall 2R, therebypositioning the upper side supporting plate 26U in the left-rightdirection. In addition, the projecting portion 29 of the upper sidesupporting plate 26U contacts a front end of the groove 30, and pawls 31formed on an upper surface of the upper side supporting plate 26U engageholes 32 provided in the top wall 2R, thereby defining a position of theupper side supporting plate 26U in the back-forth direction.

[0048] With this configuration, both right and left ends of the upperside supporting plate 26U contact the lower surface of the top wall 2Rwith elasticity. Also, there is an appropriate initial space G betweenthe lower surface of the top wall 2R and the upper surface of the upperside supporting plate 26U. Therefore, when the case 2 is deformed due tothe temperature change, the space G absorbs the deformation, therebymaintaining a constant axial force on the vertical louver blades 4.Accordingly, it is possible to reduce a change in the rotational torqueof the vertical louver blades 4 due to the deformation of the case 2caused by the temperature change.

[0049] As shown in FIG. 11, a slit 24 divides the sector gear 9 into twoparts along a surface perpendicular to the axis line. Gear teeth of thedivided two parts 9 a and 9 b are formed to have a slightly offsetpitch. The sector gear 9 is integrally formed of a synthetic resin, andthe two parts 9 a and 9 b can displace slightly with each other in thecircumferential direction due to intrinsic elasticity.

[0050] When the sector gear 9 engages the pinion 8, the pitch isshifted, and the elasticity causes a relative displacement in thecircumferential direction. Thus, the tooth surface of the sector gear 9closely contacts the tooth surface of the pinion 8, thereby preventingbacklash and improving the operation for the side dial 6.

[0051] As shown in FIG. 12, a pin 25 projecting from an end of the arm14 passes through a long hole 26 formed in an end of a comb teeth part15 a of the interlocking member 15, thereby interconnecting an end ofthe arm 14 of the horizontal louver blades 3 and the interlocking member15. A long axis of the long hole 26 is parallel to a straight line Lconnecting a middle point (α1=α2) of the rotational range of the pin 25and the center of the supporting axis 13. Therefore, it is possible tominimize a change in a frictional angle between the pin 25 and the longhole 26 when the horizontal louver blades 3 are tilted, thereby reducingloss when the multiple horizontal louver blades 3 are continuouslydriven, and reducing a change in the control force according to therotational angle.

[0052] In the above-mentioned embodiments, the present invention isapplied to the air outlet in the car compartment. However, the presentinvention is not limited to the application, and equally applicable to,for example, an air outlet for a household air conditioning system.

[0053] As described above, according to the present invention, one ofthe gears provided at the connecting portion between the manualoperating member and the damper is divided in the axial direction, andthe two divided parts are provided coaxially and have the slightlyoffset pitch so that they can displace with each other in thecircumference direction with elasticity, thereby eliminating thebacklash of the gear.

[0054] In addition, the angle of the long hole engaging the pinprojected on the louver blades is set appropriately, thereby minimizinga change in the frictional angle between the long hole and the pin whenthe louver blades are tilted. Furthermore, the rotational resistanceapplying means is provided in the rotational central axis of the manualoperating member, thereby eliminating a gap of the louver bladesinterlocked with the manual operating member.

[0055] Further, the elastic portion deformable in the axial direction ofthe louver blades is provided on the supporting plate for attaching themultiple louver blades to the air outlet, so that the elasticdeformation of the supporting plate absorbs the heat deformation betweenthe air outlet and the louver blades, thereby effectively stabilizingthe rotational torque of the vertical louver blades.

[0056] Further, the elastic portions are provided on the both ends ofthe supporting plate, or the elastic portions are branched. Thus, thesupporting plate is securely attached to the air outlet.

[0057] Also, the O-rings made of a silicone resin with self-lubricityare disposed at the supporting axis of the rotational operating portionthat moves the interlocking member in the right-left direction, therebyreducing the torque fluctuation of the rotational operating portioncaused by the temperature change.

[0058] While the invention has been explained with reference to thespecific embodiments of the invention, the explanation is illustrativeand the invention is limited only by the appended claims.

What is claimed is:
 1. A regulator for regulating airflow in an airoutlet, comprising: a case having a flange with the air outlet, aplurality of louver blades arranged at the air outlet for controlling adirection of the airflow and having axes at longitudinal ends, at leastone interconnecting member connected to the louver blades for changingthe direction of the airflow, and a supporting member attached to theflange at the air outlet and having axis holes for receiving the axes ofthe louver blades, said supporting member having an elastic portion forallowing deformation thereof in an axis direction of the louver blades.2. A regulator according to claim 1, wherein said elastic portion isformed at two longitudinal ends of the supporting plate.
 3. A regulatoraccording to claim 2, wherein said elastic portion has a branched shape,an end of which contacts the flange.
 4. A regulator according to claim1, further comprising an operating member rotatably supported on thecase and having a shaft, said operating member being connected to theinterconnecting member for tilting the louver blades, and rotationalresistance applying means provided around the shaft of the operatingmember.
 5. A regulator according to claim 4, wherein said rotationalresistance applying means is formed of an O-ring between the shaft and asupport thereof.
 6. A regulator according to claim 5, wherein saidO-ring is formed of a silicone resin having self-lubricity.
 7. Aregulator according to claim 1, further comprising an operating memberrotatably supported on the case for tilting the louver blades, and aninterconnecting member disposed between the louver blades and theoperating member and having long holes for receiving the pins of thelouver blades, each of said long hole having a long axis parallel to astraight line between a middle point of a rotational range of the pinand the rotational center of the louver blade.
 8. A regulator forregulating airflow in an air outlet, comprising: a case having the airoutlet and an air path, a plurality of louver blades arranged at the airoutlet for controlling a direction of the airflow, a damper disposed inthe air path of the case for opening and closing the air path, anoperating member rotatably attached to the case and connected to thelouver blades and the damper for tilting the same, and connecting meansfor connecting the damper to the operating member and having first andsecond gears portions meshing each other and connected to the operatingmember and the damper, one of said first and second gear portions havingdivided teeth portions perpendicular to a shaft thereof, said dividedgear teeth portions having pitches slightly offset in a circumferencedirection with each other so that the two gear teeth portions displacein the circumference direction when the first and second gear portionsengage with each other.
 9. A regulator according to claim 8, whereinsaid connecting means further includes a lever connected to the damperwith a pin, and an arm rotationally attached to the case and having anelongated hole engaging the pin of the lever, said one of the first andsecond gear portions being formed on the arm away from the elongatedhole.
 10. A regulator according to claim 9, further comprising aninterlocking member connected to the louver blades for changingdirections thereof, said interlocking member being connected to theoperation member.
 11. A regulator for regulating airflow in an airoutlet, comprising: a case having the air outlet and an air path, aplurality of louver blades arranged at the air outlet for controlling adirection of the airflow, each louver blade having a rotational centerand a pin projecting at a position away from the rotational center, anoperating member rotatably supported on the case for tilting the louverblades, and an interconnecting member disposed between the louver bladesand the operating member and having long holes for receiving the pins ofthe louver blades, each of said long hole having a long axis parallel toa straight line between a middle point of a rotational range of the pinand the rotational center of the louver blade.